Tile saw

ABSTRACT

A tile saw includes a base, a frame assembly disposed on the base, a first rail disposed on the frame assembly, the first rail having a longitudinal axis. A table is slidingly disposed on the first rail and a support assembly is disposed on the base. A saw assembly is supported by the support assembly and includes a motor within a motor housing, and a cutting wheel driven by the motor. The motor housing has an inlet for allowing air into the motor housing, a serpentine path within the motor housing, between the inlet and the motor, for directing air through the motor housing, and a filter within the motor housing.

This application is a continuation of U.S. patent application Ser. No.10/688,668, entitled “Tile Saw,” filed Oct. 17, 2003, now U.S. Pat. No.8,286,539, which claims the benefit of U.S. Provisional Application No.60/423,335, filed Nov. 1, 2002, each of which are incorporated herein byreference.

FIELD OF THE INVENTION

This invention relates generally to tile or masonry saws and, moreparticularly, to tile saws with expanded capacity.

BACKGROUND OF THE INVENTION

A typical tile saw includes a base which supports a generally flat tabletop. A saw unit may be disposed on the base or table for cutting aworkpiece, such as a tile or masonry brick, disposed on the table.However, the maximum cutting capacity of such tile saws is limited bythe size of the machine, i.e., the envelope.

Accordingly, persons skilled in the art have devised a tile saw wherethe base has two tracks and the table has bearings or wheels riding onthe tracks, so that the table can be slid relative to the saw unit forincreased capacity. Such tile saws, however, are usually susceptible todust collecting between the tracks and wheels, which creates bindingbetween the base and the table. Ultimately, the binding may causeuneven, inaccurate cuts, which may translate into loss of time,materials and/or profit for the user.

Further, the capacity of such tile saws is usually limited to the lengthof the tracks. In other words, if a user wants increased capacity, hemay have to lengthen the tracks. However, longer tracks may result inless portability of the tile saw.

It is therefore an object of this invention to provide a saw withincreased cutting capacity without sacrificing portability.

SUMMARY OF THE INVENTION

In accordance with the present invention, an improved tile saw isemployed. The saw comprises a base, a frame assembly disposed on thebase, a first rail disposed on the frame assembly, the first rail havinga longitudinal axis, a table slidingly disposed on the first rail, asupport assembly disposed on the base, a saw assembly supported by thesupport assembly, the saw assembly comprising a motor, a cutting wheeldriven by the motor, the saw assembly being pivotable about a horizontalaxis substantially parallel to the longitudinal axis, and a switchelectrically connected to the motor and disposed on the support assemblyso that, when the motor assembly is pivoted about the horizontal axis,the switch remains stationary.

Additional features and benefits of the present invention are described,and will be apparent from, the accompanying drawings and the detaileddescription below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate preferred embodiments of theinvention according to the practical application of the principlesthereof, and in which:

FIG. 1 is a front perspective side view of a tile saw according to thepresent invention;

FIG. 2 is a rear perspective view of the tile saw illustrated in FIG. 1;

FIG. 3 illustrates a frame assembly according to the present invention,where FIGS. 3A-3B are a perspective view and a close-up view of theframe assembly, respectively;

FIG. 4 is a partially exploded view of the frame and column assembliesaccording to the present invention;

FIG. 5 illustrates a kerf fence assembly on a table assembly accordingto the present invention, where FIGS. 5A-5C are front views of thefirst, second and third embodiments, respectively, and FIG. 5D is apartial top plan view of the fourth embodiment according to the presentinvention;

FIG. 6 illustrates a first embodiment of the rail and table assembliesaccording to the present invention, where FIGS. 6A-6C are partialcross-sectional views along line A-A of FIG. 1, and lines B-B and C-C ofFIG. 6A, respectively;

FIG. 7 illustrates a detail of the rail and table assemblies of FIG. 6,where FIGS. 7A-7B are a partial perspective view and a partial top planview, respectively;

FIG. 8 is a partial cross-sectional view (taken along line A-A ofFIG. 1) of a second embodiment of the rail and table assembliesaccording to the present invention;

FIG. 9 is a partial cross-sectional view of a table assembly accordingto the present invention;

FIG. 10 is a perspective view of a table assembly with a firstembodiment of a collector assembly according to the present invention;

FIG. 11 is a front view of a table assembly with a second embodiment ofa collector assembly according to the present invention;

FIG. 12 is a partially exploded view of the column assembly according tothe present invention;

FIG. 13 illustrates the arm and motor assemblies according to thepresent invention, where FIGS. 13A-13B are front and rear perspectiveviews, respectively;

FIG. 14 illustrates the blade at two different bevel positions;

FIG. 15 illustrates several embodiments of a depth stop mechanismaccording to the invention, where FIGS. 15A-15C and 15E are side viewsof the first, second, third and fourth embodiments, respectively, FIG.15D is a partial cross-sectional view of the third embodiment along lineF-F of FIG. 15C, and FIG. 15F is a partial cross-sectional view of afifth embodiment;

FIG. 16 is a circuit schematic of the tile saw according to the presentinvention;

FIG. 17 illustrates an adjustable guard assembly according to thepresent invention, where FIGS. 17A-17B show the adjustable guardassembly in two different positions;

FIG. 18 illustrates a fluid nozzle assembly according to the presentinvention, where FIGS. 18A-18B show the fluid nozzle assembly in thedetached and attached positions, respectively;

FIG. 19 is a side view of the tile saw with a flexible nozzle assemblyaccording to the present invention;

FIG. 20 illustrates the lower portion of the nozzle assembly, whereFIGS. 20A-20B are front and side views of the nozzle assembly,respectively;

FIG. 21 is a partial perspective view of the fluid nozzle assembly witha detached hose;

FIG. 22 is a perspective view of a portion of the guard assembly;

FIG. 23 is a partial cross-sectional view of the guard assembly with aflap assembly;

FIG. 24 illustrates the fluid direction mechanisms within the motorhousing, where FIG. 24A is a front view of the motor assembly, and FIGS.24B-24C are partial cross-sectional views along lines D-D and E-E ofFIG. 24A, respectively;

FIG. 25 is a partial side view of the tile saw supported by a stand;

FIG. 26 illustrates the cutting capacity of the tile saw according tothe invention, where FIGS. 26A-26B are side and a partial top view alongline XX of FIG. 26A, respectively;

FIG. 27 illustrates two alternate designs of an angle guide assembly,where FIGS. 27A-27B are a perspective view of the first design and apartial exploded view of the second design, respectively;

FIG. 28 illustrates two alternate designs of the angle guide clampingmechanism, where FIGS. 28A-28B are partial cross-sectional views of thefirst and second designs, respectively;

FIG. 29 is a partial cross-sectional view of a first embodiment of astop assembly for the angle guide clamping mechanism; and

FIG. 30 is a perspective view of a second embodiment of the stopassembly for the angle guide clamping mechanism.

DETAILED DESCRIPTION

The invention is now described with reference to the accompanyingfigures, wherein like numerals designate like parts. FIGS. 1-2illustrates a first embodiment of the present invention, where tile saw10 comprises a base 11. A frame assembly 20 may be disposed on base 11.Frame assembly 20 may support rail assembly 30 and table assembly 40,which is movable along rail assembly 30. Frame assembly 20 may alsosupport a column assembly 50, which in turn may support an arm assembly60. Arm assembly 60 may support motor assembly 70, which includes acutting wheel 76 for cutting a workpiece (not shown), such as tile,disposed on table assembly 40 and moved into contact with the cuttingwheel 76.

Base 11 is preferably injection molded or vacuum formed as a tub forsupporting the different elements of the tile saw 10 as described below.Base 11 may be made of polypropylene with calcium carbonate filler, suchas Astryn 75A6-2 by Basell, HDPE (High Density Polyethylene) or ABS.

As is well known in the art, base 11 is preferably shaped as a tub toreceive most, if not all, the water and slurry created during operation.A pump 90 is preferably disposed on base 11 to pump fluid out of base11.

To maximize the amount of water and slurry received by base 11, it maybe preferable to extend base 11 by providing extension pans. As shown inFIGS. 1-2, extension pan 12 can be attached to the rear of base 11 viathumbscrews 13. Alternatively, base 11 may have a lip 11L. Extension pan12 may be shaped so that it is placed on or snapped unto lip 11L.

Persons skilled in the art will recognize that other extension pans maybe attached to the sides or front of base 11. These extension pans arepreferably injection molded or vacuum formed and made of ABS, styrene,polypropylene, or HDPE.

Referring to FIG. 25, base 11 (and thus tile saw 10) may be supported bya stand S. Preferably, base 11 has at least one notch 11N that mayextend through the entire width of base 11 or just through a portion ofthe width of base 11. Stand S has beams SB which are disposed withinnotches 11N. Preferably, the beams SB have a profile which matches theprofile of notches 11N.

Persons skilled in the art should recognize that, if the stand S has alinkage that limits the distance between beams SB, one beam SB may bedisposed within one notch 11N, while the other beam SB may just contactthe underside of base 11.

A beam SB may be retained within notch 11N by a plate 15 which capturethe beam SB. Preferably, plate 15 is attached to the base 11 via a screw15S. Plate 15 may be rotated about the longitudinal axis of the screw15S or about an axis substantially perpendicular to the longitudinalaxis of the screw 15S to allow the user to insert beam SB into notch11N. Once the beam SB is in place, the user can rotate plate 15 to itsoriginal position in order to capture beam SB.

Base 11 may support frame assembly 20. Referring to FIGS. 1-3, frameassembly 20 may have a body 21 with front and rear extensions 24. Base11 may have notches 14 which receive extensions 24.

Preferably, frame assembly 20 is made of cast aluminum. Such material isadvantageous as it reduces the flex caused by the tile saw componentsdisposed thereon, providing a more accurate cut.

In addition, frame assembly 20 may have integral storage areas forstoring tile saw components thereon. For example, frame assembly 20 mayhave a pump holder assembly 22 for holding pump 90 during transport.Pump holder assembly 22 may include a shelf 22S extending from body 21.Shelf 22S may have holes 22H thereon to allow fluid and slurry to falltherethrough. A wall 22W disposed around shelf 22S may retain pump 90 inplace. It would also be preferable to provide a hole 22SH in a side wallof body 21 to allow the user to insert a stem protrusion 91 of pump 90therein, in order to retain pump 90 more securely.

Referring to FIGS. 1-4 and 12, frame assembly 20 may support columnassembly 50. Column assembly 50 may be made of cast aluminum and mayhave a body 51. Preferably, body 51 is screwed unto a support pad 23 offrame assembly 20 via screws 23S.

It is preferable to provide a means to ensure proper alignment betweenthe column assembly 50 and frame assembly 20. Accordingly, posts 23W,23N may be provided on support pad 23 and/or column body 51. These postsare received in corresponding holes in column body 51 and/or support pad23. Preferably, post 23W is wider than post 23N. Accordingly, the userneed only dispose body 51 unto support pad 23. The posts 23W, 23N (andthe corresponding holes) enable the user to quickly locate the properposition of column assembly 50 relative to frame assembly 20. Oncelocated, the user need only affix column assembly 50 to frame assembly20 via screws 23S.

Persons skilled in the art will recognize that the holes receiving posts23W, 23N are preferably close tolerance holes. In order to allow bothposts 23W, 23N to fit in both holes, some side-to-side allowance for oneof the holes should be provided. This side-to-side allowance could beachieved by making one of the holes into a slot, or shaping one post asa diamond, in a similar manner as post 51D, discussed below.

Referring to FIGS. 1-2 and 6-7, frame assembly 20 may support railassembly 30. Rail assembly 30 in turn preferably supports table assembly40. A first embodiment of rail assembly 30 may include a first rail 31and a second rail 35, both rails being preferably supported by frameassembly 20. Both first and second rails 31, 35 may be made of extrudedor cast aluminum.

First rail 31 is preferably fixed to frame assembly 20 via a bolt andnut combination 32. First rail 31 may have a first portion 31C which issubstantially C-shaped cross-section throughout a major portion, if notall, of its entire length. In addition, first rail 31 may include asecond portion 31P which includes a rail or rod 31R. First and secondportions 31C, 31P may be interconnected. Preferably rod 31R lies outsideof the first portion 31C.

Second rail 35 is preferably fixed to frame assembly 20 via a bolt andnut combination 34. Second rail 35 preferably has a substantiallyL-shaped or C-shaped cross-section throughout a major portion, if notall, of its entire length.

Table assembly 40 is preferably movably connected to rail assembly 30.Table assembly 40 includes a table body 41 having at least one groove41G. Table body 41 may be made of cast aluminum. Table body 41 may haverubber portions 42 overmolded thereon to protect a workpiece placed ontable assembly 40.

Table assembly 40 may also include several shafts 43 connected to tablebody 41. Shafts 43 may be fixedly attached to table body 41 (as shown inFIG. 8). Alternatively, shafts 43 may be supported by bearings 43Bdisposed between table body 41 and shafts 43. Bearings 43B may be ballor roller bearings.

A wheel 44 may be disposed on shaft 43. Bearings may be disposed betweenwheel 44 and shaft 43. Preferably, two bearings are pressed into eachwheel 44. In addition, a bearing 45 may be disposed on shaft 43. Bearing45 may be a rotatable roller or a non-rotatable element which may bepolygonnally shaped. Preferably, shafts 43, wheels 44 and bearings 45are disposed on one side of the table body 41.

At least one bearing 46 may be disposed on the other side of table body41. Bearing 46 may be a rotatable roller, as shown in FIG. 6A. Bearing46 may be disposed on a shaft 46S connected to table body 41. Shaft(s)46S may be fixedly attached to table body 41. Alternatively, shaft(s) 43may be supported by bearings disposed between table body 41 and shafts43. Bearings 43B may be ball or roller bearings.

Bearings 46B may be disposed between bearing 46 and shaft 46S.Preferably, two bearings 46B are pressed into each bearing 46.

Bearing 46 preferably rides on second rail 35.

Alternatively, bearing may be a non-rotatable element, such as linearbearing 49 shown in FIG. 8. Such linear bearing may ride on second rail35 or travel underneath second rail 35 so that the user cannot pull upsuch end beyond second rail 35.

With such arrangement, the table assembly 40 may be slidably disposed onrail assembly 30 along a longitudinal axis X (as shown in FIG. 1)defined by rail assembly 30. In particular, wheels 44 may be disposed onrod 31R, while bearings 45, 46 are disposed within first portion 31C andsecond rail 35, respectively.

Preferably, wheels 44 and bearings 45 support most, if not all, of theweight of the table body 41. In the present arrangement, table body 41preferably pivots about the contact between rod 31R and wheels 44.Referring to FIG. 6A, as table body 41 rotates in a clockwise direction,bearings 45 contact the inside portion of first portion 31C.

Table body 41 may thus be moved in a direction parallel to thelongitudinal axes of first and second rails 31, 35. When table body 41is moved accordingly, wheels 44 rotate about and/or with shafts 43,while bearings 45 slide along first portion 31C.

This arrangement is especially advantageous as it allows the user tomove the table assembly 40 beyond the ends of rail assembly 30, as shownin FIGS. 1-2. Persons skilled in the art will recognize that, as eachwheel 44 moves beyond the front end of rod 31R (except for one or two ofthe rearmost wheels 44), bearings 45 will contact the inside, upperportion of the first portion and second rail 31C, 35, to support thetable assembly 40 in a first cantilevered position. Similarly, personsskilled in the art will recognize that, as each wheel 44 moves beyondthe rear end of rod 31R (except for one or two of the fowardmost wheels44), bearings 45, 46 will contact the inside, upper portion of the firstportion and second rail 31C, 35, to support the table assembly 40 in asecond cantilevered position.

Having the ability to move the table assembly 40 into at least one ofthe first and second cantilevered positions allows for a longer movementrange of table assembly 40, which in turn results in an extended cuttingcapacity without increasing the length of the rail assembly 30 and/orbase 11. For example, the tile saw shown in FIG. 26 may have a cuttingwheel 76 with a diameter of about 10 inches, a distance CA between thewheel axis WA and the front of base 11 of about 60.56 centimeters (or adistance CA′ between the wheel axis WA and the front of base 11,including lip 11L, of about 62.18 centimeters), and a distance CCbetween the column body 51 and the plane containing cutting wheel 76 ofabout 33.4 centimeters, may cut a workpiece T about 25 inches (63.5centimeters) long disposed on table body 41 at a workpiece angle TA of0° in one pass. The same tile saw could also cut a square workpiece Thaving sides of about 24 inches along its major diagonal MD (i.e.,workpiece T being disposed at a workpiece angle TA of 45°) in twopasses.

Persons skilled in the art should also recognize that table assembly 40can only be inserted into and/or removed from rail assembly 30 by movingtable assembly in a direction parallel to the longitudinal axes of firstand second rails 31, 35. It may be desirable to provide first portion31C and second rail 35 with openings on their respective upper portionsto allow the user to lift off table saw assembly 40 when bearings 45, 46are aligned with said openings. Persons skilled in the art willrecognize that multiple sets of openings can be provided on firstportion 31C and second rail 35 so that the user can lift off table sawassembly 40 at multiple locations.

Table body 41 may have downwardly extending lips 41L, which preferablypartially cover first and/or second rails 31, 35. This may limit theamount of fluid and/or slurry that enters first and/or second rails 31,35.

Referring to FIG. 6C, it is preferable to make at least one of wheels 44axially movable relative to its shaft 43. This ensures a betteralignment between the wheels 44 and rod 31R. Preferably, the centerwheel(s) 44 will be axially movable. Another advantage of providing suchadjustability is that, if wheels 44 have grooves 44G for riding on rod31R, the width of the grooves 44G can be minimized regardless of themanufacturing tolerances. This in turn may minimize any sideways wobbleof the table assembly 40 when it is in a cantilevered position, thusproviding a better quality cut.

Referring to FIG. 6B, it is preferable to provide a height differentialbetween bearings 45 to prevent binding during sliding. For example, in atable assembly 40 having three bearings 45, the center bearing may bedisposed a tad higher than the rearmost bearing, creating a heightdifferential G1. Similarly, the center bearing may be disposed a tadhigher than the forwardmost bearing, creating a height differential G2.Preferably, height differentials G1, G2 are substantially equal and arepreferably between about 1 mm and about 5 mm.

It is preferable to provide a method for adjusting the rail assembly 30so that table assembly 40 moves in a direction substantially parallel tothe cutting wheel 76. Referring to FIG. 7, rod 31R is supported by frontand rear supports 31FS, 31RS, respectively. Screws 31SSF, 31SSRpreferably attach corresponding front and rear supports 31FS, 31RS toframe assembly 20. Preferably, rear support 31RS (and thus rod 31R) canpivot about screw 31SSR, whereas front support 31FS has a slot 31FSS toallow such pivoting action. Screw 31SSR is preferably aligned with therotating axis WA of cutting wheel 76. Persons skilled in the art willrecognize that screw 31SSR may be replaced by a pin, cast boss, etc., solong as rod 31R can only be pivoted about one axis, which is alignedwith rotating axis WA.

Persons skilled in the art will recognize that this adjustment mechanismmay also be used with second rail 35. In addition, persons skilled inthe art should recognize that, while only rod 31R is being shown in FIG.7, the entire first rail 31 is adjustable as it is interconnectedconnected to rod 31R.

FIG. 8 illustrates another adjustment mechanism 33 that can be used forpivoting first rail 31 about one pivot axis (if the first rail 31 pivotsabout one axis and has one adjustment mechanism 33), or for adjustingfirst rail 31 at multiple locations throughout its length (if multipleadjustment mechanisms 33 are provided). Basically, adjustment mechanism33 may include an adjustment screw 33AS, a cylinder 33C threadinglyengaged to the adjustment screw 33AS, and a locking screw 33LS extendingthrough first portion 31C, frame body 21 and threadingly engagingcylinder 33C. Adjustment screw 33AS preferably threadingly engages framebody 21 or an extension 21E thereof.

To adjust the alignment of first rail 31, the user needs to loosenlocking screw 33LS and then rotate adjustment screw 33AS. As adjustmentscrew 33AS is rotated, it horizontally moves cylinder 33C (and thusfirst rail 31). When the desired position is obtained, the user can fixthe position of first rail 31 by just tightening locking screw 33LS,which urges first portion 31C against frame body 21.

Referring to FIGS. 1-2 and 5, as table assembly 40 is moved towardscutting wheel 76, cutting wheel 76 cuts a workpiece T disposed on tablebody 41 and extends below the top surface of table body 41 into one ofthe grooves 41G disposed thereon. Table body 41 may have an upwardlyextending fence 41F for supporting workpiece T as it is being moved intoand/or cut by cutting wheel 76.

In order to avoid cutting wheel 76 cutting into table body 41, it istypical to widen grooves 41G. However, such wider grooves 41G do notindicate the user where the workpiece T will be cut. Accordingly, it ispreferable to provide a means to indicate the cutting path of cuttingwheel 76, i.e., where the workpiece T will ultimately be cut.

One such means is shown in FIG. 5A. Basically, an insert 46 is disposedon fence 41F to cover groove 41G. During manufacture or assembly, thetable assembly 40 is slid towards cutting wheel 76, until insert 46 iscut by cutting wheel 76. Insert 46 will thus have a cut line CL showingwhere the cutting wheel 76 cuts through. This allows the user to alignthe workpiece T to the cutting wheel 76.

Preferably, insert 46 is made of a material that does not damage thecutting wheel 76 or melt upon contact with the cutting wheel 76.Accordingly, insert 46 may be made of phenolic plastic or any othersuitable material, such GE Noryl PPO.

It is preferable to design insert 46 so that it can be removed forreplacement. Accordingly, insert 46 is preferably attached to fence 41via screws 46S.

An alternate design of insert 46 is shown in FIGS. 1 and 5B, where likenumerals refer to like parts, and where the teachings of the previousembodiment are wholly incorporated herein. In this embodiment, insert46′ is substantially cylindrical and inserted into fence 41F. Insert 46′may have portions 46C of decreased width, which can contact the screws46S. Having a substantially cylindrical insert 46′ is advantageous asthe insert 46′ can be rotated to an uncut portion when necessary ordesired, rather than requiring a full replacement every time.

FIG. 5C illustrates another means for indicating the cutting wheel. Inthis embodiment, an element 48 is slidably attached to fence 41F. Whenthe table assembly 40 is moved towards the cutting wheel 76, the usercan slide element 48 against or close to cutting wheel 76 and fix itslocation by tightening screws 48S. The leftmost edge will thus indicatethe cutting path of cutting wheel 76.

While it is not necessary to cut element 48, some users may still desireto do so. Accordingly, it is preferable to make element 48 of a materialthat does not damage the cutting wheel 76 or melt upon contact with thecutting wheel 76. Accordingly, element 48 may be made of phenolicplastic or any other suitable material, such GE Noryl GPS.

Referring to FIG. 5D, an insert 47 may be disposed on fence 41F. Theteachings of the previous embodiments are incorporated herein. Insert 47is advantageous as, in addition to indicating the cutting path via cutline CL, it has two inclined edges 47M, allowing the user to placeworkpiece T in a mitered position. Preferably, the two inclined edges47M are substantially perpendicular. In addition, each inclined edge 47Mforms an angle of 45° with the cut line CL, so that the user can cutdiagonally through a square tile.

As mentioned above, table body 41 preferably has grooves 41G. Referringto FIG. 9, grooves 41G may have a bottom wall 41GB, which slopesdownwardly from the front and rear ends of table body 41 to the centerof table body 41. Fluid and/or slurry generated during the cuttingoperation may exit table body 41 through a drain hole 41D provided atthe center of bottom wall 41GB. It is preferable to provide drain hole41D near the center of table body 41 so that drain hole 41D can draininto base 11 regardless of whether table body 41 is within the envelopeof base 11 or whether table body 41 is in the front and/or rearcantilevered positions.

Alternatively, fluid and/or slurry generated during the cuttingoperation may exit table body 41 through holes 41GBH, which in turn maydrain into a draining pan 41RD. Draining pan 41RD preferably has abottom wall which slopes downwardly from the rear end of table body 41towards the drain hole 41D. The fluid and/or slurry exiting throughdrain hole 41D ends up in base 11.

Draining pan 41RD may also have a substantially horizontal baffle 41Hdisposed below the top surface of table body 41 and cutting wheel 76.Baffle 41H would catch some of the fluid and/or slurry that is thrownrearwardly due to the rotation of the cutting wheel 76 and redirect suchfluid and/or slurry into the draining pan 41RD.

Table body 41 may also have a brush 41B at the rearward and/or forwardends of grooves 41G to help limit the flow of fluid and/or slurry beyondthe brush 41B and/or grooves 41G. Preferably, the brush 41B has bristlesmade of nylon or a synthetic rubber-like material.

Referring to FIG. 10, it is preferable to provide table assembly 40 withan extension pan assembly 41E which can further assist in redirectingfluid and/or slurry generated during the cutting operation into base 11.In particular, extension pan assembly 41E can be attached to table body41 via screws 41ES. Extension pan assembly 41E preferably has a bottomwall 41EB which preferably extends downwardly from its outermost edgetowards table body 41. A rib 41ERR may help separate bottom wall 41EBfrom table body 41. Extension pan assembly 41E may be blow molded,injection molded or vacuum formed and may be made of ABS, styrene,polypropylene, or HDPE.

FIG. 11 illustrates an alternate embodiment of extension pan assembly41E, where like numerals refer to like parts. The teachings of theprevious embodiment are wholly incorporated herein. The main differencebetween the previous and present embodiment is that the extension panassembly 41E is fixed in the previous embodiment, whereas the extensionpan assembly 41E is movable.

In the present embodiment, extension pan assembly 41E is slidablyattached to rod 41ER, which in turn is fixed to table body 41 via abracket 41EB and screws 41EBS. Rod 41ER may have holes 41ERH which canreceive a detent 41ED which is connected to extension pan assembly 41E.Preferably detent 41ED is biased towards holes 41ERH. A handle 41EDH canmove detent 41ED away from hole 41ERH to allow movement of extension panassembly 41E. in an embodiment, extension pan assembly 41E is moveablein a direction Y that is substantially perpendicular to the longitudinalaxis X defined by rail assembly 30 (see also FIG. 1).

Referring to FIGS. 27-30, an angle guide assembly 65 may be attached totable body 41 to help guide a workpiece T disposed on table body 41 intocutting wheel 76. Angle guide assembly 65 may have a guide body 65B thatis disposable on table body 41. Preferably, guide body 65B is clampedunto fence 41F.

Guide body 65B may have a clamping channel 65C which receives fence 41F.Clamping channel 65C may include a surface 65CS which is preferablysubstantially parallel to fence 41F. Guide body 65B may also include amovable plate 65P which is moved into contact against fence 41F forsandwiching the fence 41F between surface 65CS and plate 65P. Plate 65Pmay be moved in by a knob 65K which is preferably attached to a screw65KS, which in turn is preferably threadingly engaged to guide body 65Band may contact plate 65P.

As shown in FIG. 28A, plate 65P may be attached to guide body 65B viascrews 65PS. In such case, plate 65P is preferably made of spring steel,so that screw 65KS is loosened, plate 65P moves away from fence 41F.

Alternatively, plate 65P may just be connected to a shaft or screw 65PP,which extends into and/or through guide body 65B, as shown in FIG. 28B.A spring 65PPS captured between screw 65PP and guide body 65B may biasplate 65P away from fence 41F, so that screw 65KS is loosened, plate 65Pmoves away from fence 41F.

Guide body 65B may have a surface 65BP on one side thereof, andpreferably two surfaces 65BP on both sides thereof. Surfaces 65BP arepreferably substantially perpendicular to surface 65CS. Accordingly,guide body 65B can be attached to table body 41 and a workpiece T can bedisposed against fence 41F and surface 65BP. Persons skilled in the artwill recognize that, if two surfaces 65BP are provided on both sides ofguide body 65B, the user could rest a workpiece T against a surface 65BPregardless on which side of groove 41G the guide body 65B is disposed.

Angle guide assembly 65 may also have an angled fence 65F. Angled fence65F may be pivotably attached to guide body 65B, as shown in FIG. 27A,so that it can be pivoted to either side of guide body 65B. Preferably,angled fence 65F is pivotable about an axis 65A which is substantiallyparallel to surfaces 65BP and/or substantially perpendicular to surface65CS.

Alternatively, angled fence 65F may be removably disposed on guide body65B, as shown in FIG. 27B. In this case, angled fence 65F would includea boss 65FB, which can be slid into a slot 65BSS of support wall 65BS.The user can thus remove angle fence 65F, rotate it, and disposed on theother side of guide body 65B by sliding boss 65FB into slot 65BSS.Persons skilled in the art will recognize that angled fence 65F may havetwo bosses 65FB received into rear and front slots 65BSS of guide body65B.

Angled fence 65F has a surface 65FS which is preferably substantiallyperpendicular to the support surface of table body 41, though personsskilled in the art will recognize that surface 65FS may be angledrelative to table body 41. In addition, surface 65FS is preferablyangled relative to axis 65A and/or surfaces 65BP. Preferably, surface65FS is disposed at an angle of 45° relative to axis 65A and/or surfaces65BP, so that the user can support a workpiece T disposed on table body41 at an angle.

Persons skilled in the art will recognize that providing an angled fence65F that can be moved between both sides of guide body 65B will enablethe user to support a workpiece T disposed on table body 41 at an angleregardless of which side of groove 45G guide body 65B is disposed.

Angled fence 65F may have support ribs 65FR for added strength and/orstability.

Guide body 65B may also carry set screws 65SS for properly aligning thesurface 65FS relative to table body 41 and/or surfaces 65BP.

It may be advantageous to provide a stop assembly on angled fence 65Fwhich location the user can fix so that the user can set a desired cutand easily make this cut multiple times. One embodiment of such stopassembly is shown in FIG. 29, where stop assembly 66 is disposed onangled fence 65F. Stop assembly 66 may have a surface 66S which ispreferably substantially perpendicular to surface 65FS. Preferably, thelocation of stop assembly 66 is fixed relative to angled fence 65F via ascrew 66S.

Another embodiment of a stop assembly is shown in FIG. 30. In thisembodiment, angled fence 65F may have two coplanar portions 65FP whichdefine surface 65FS′. A rod 67R may be slidably attached to angled fence65F and/or portions 65FP. Rod 67R may carry a stop 67S, which wouldcontact the workpiece T. The position of stop 67S may be fixed relativeto angled fence 65F via a screw 67SS which is threadingly engaged toportion 65FP and contacts rod 67R.

Referring to FIGS. 1-2, 4 and 12, column assembly 50 may be supported byframe assembly 20. Column assembly 50 in turn may support arm assembly60.

Column assembly 50 preferably includes a column body 51. Column body 51is preferably hollow and made of cast aluminum. Ribs 51R may be disposedwithin column body 51 to increase its strength.

It is preferable to route all the electrical wires necessary to providepower to the motor 78M through column body 51 and arm assembly 60. Aplate 52 may be used to cover and/or seal the inner cavity of columnbody 51 that contain the electrical wires. Plate 52 may also support theincoming power cable 54, which may then extend through the inner cavityof column body 51 and into the arm assembly 60. In addition, plate 52may also support a power outlet 53, which can be used to power any otherelectrical device, such as pump 90. Plate 52 may be affixed to columnbody via screws 52S.

It is preferable to provide a means to ensure proper alignment betweenthe column assembly 50 and arm assembly 60. Accordingly, posts 51W, 51Dmay be provided on column body 51 and/or arm assembly 60. These postsare received in corresponding holes in arm assembly 60 and/or columnbody 51.

Preferably the holes receiving posts 51W, 51D are close tolerance holes.In order to allow both posts 51W, 51D to fit in both holes, someside-to-side allowance for one of the holes should be provided. Thisside-to-side allowance could be achieved by making one of the holes intoa slot, or shaping one post, such as post 51D, as a diamond.

Accordingly, the user need only dispose arm assembly 60 unto column body51. The posts 51W, 51D (and the corresponding holes) enable the user toquickly locate the proper position of column assembly 50 relative to armassembly 60. Once located, the user need only affix arm assembly 60 tocolumn assembly 50 via screws 51S.

Referring to FIGS. 1-2 and 13, arm assembly 60 preferably has a body 61which is substantially U-shaped. Preferably arm body 61 is substantiallyhollow to allow the electrical wires to extend therethrough. Arm body 61may pivotably support motor assembly 70. Preferably, arm body 61supports motor assembly 70 at both ends thereof.

Motor assembly 70 preferably comprises a motor 78M and a housing 78covering motor 78M. Housing 78 may be attached to a pivot arm 71. Motor78M preferably drives a spindle 72, which carries a cutting wheel 76.Cutting wheel 76 may be partially covered by guard assembly 80, asdescribed more fully below.

Pivot arm 71 preferably has front and rear ends. At the rear end, pivotarm 71 may be pivotably attached to chopping trunnion 73 so that pivotarm 71 (and motor 78M and housing 78) can pivot about axis 73A. Choppingtrunnion 73 is preferably pivotably connected to bevel trunnion 63,which in turn may be fixedly connected to arm body 61.

At the front end, pivot arm 71 may be movably connected to front plate74. Referring to FIGS. 1-2, 13 and 15F, a screw 74KS may be threadinglyengaged to pivot arm 71 and/or knob 74K. Front plate 74 in turn may bepivotably attached to the front end of arm body 61.

Preferably, axis 73A is substantially horizontal (at the 0° bevelposition). Such arrangement allows the pivot arm 71 (and motor 78M andhousing 78) to move downwardly in a chopping action so that a user cancut a tile in a chopping motion, or adjust the depth of cut of thecutting wheel 76. The user can fix the depth of cut of the cutting wheel76 by rotating knob 74K, which in turn lockingly contacts front plate74.

Persons skilled in the art should recognize that the user can use knob74K to pivot the pivot arm 71 (and motor 78M and housing 78) downwardly.Alternatively, housing 78 may have a handle 78H extending therefrom toassist in the chopping operation. Preferably handle 78H has asubstantially horizontal portion 78HH for the user to grasp.

It may be desirable to provide a height adjustment stop mechanism tolimit the chopping motion range of cutting wheel 76. Differentembodiments of such stop mechanisms are shown in FIG. 15, where likenumerals refer to like parts. Referring to FIG. 15A, chopping trunnion73 may carry a stop 73SS, such as a boss or bolt, which contacts asurface 71S of pivot arm 71. Alternatively, pivot arm 71 may carry astop 71SS, such as a boss or bolt, which contacts a surface 73S ofchopping trunnion 73, as shown in FIG. 15B. In order to adjust the endof the chopping range, the user need only adjust stop 71SS or 73SS.

Another height adjustment stop mechanism is shown in FIGS. 15C-15D,where like numerals refer to like parts. Chopping trunnion 73 may have aslot 73R. A shaft 73SKS may extend through slot 73R. Shaft 73SKS may bethreadingly engaged to a knob 73SK and/or a stop 73SB, which wouldcontact surface 71S of pivot arm 71. In order to adjust the end of thechopping range, the user would loosen knob 73SK, move theknob/shaft/stop combination to the desired position and tighten knob73SK.

FIG. 15E shows another height adjustment stop mechanism, where likenumerals refer to like parts. A plate 73P is preferably attached tochopping trunnion 73. Plate 73P may be pivotally attached to choppingtrunnion 73 and is preferably attached so that it pivots about axis 73A.A knob 73PK extending through plate 73P and threadingly engagingchopping trunnion 73 can fix the location of plate 73P. Pivot arm 71 inturn preferably has a stop barrel 71SB, which, as pivot arm 71 isrotated, contacts a surface 73PS of plate 73P. In order to adjust theend of the chopping range, the user would loosen knob 73PK, move theplate 73P to the desired position and tighten knob 73PK.

Another height adjustment stop mechanism 74SS is shown in FIG. 15F,where like numerals refer to like parts. A shaft 74SKS may extendthrough the slot 74S of front plate 74. Shaft 74SKS may be threadinglyengaged to a knob 74SK and/or a stop 74SB, which would contact a surfaceof pivot arm 71 or of shaft 74KS. In order to adjust the end of thechopping range, the user would loosen knob 74SK, move theknob/shaft/stop combination to the desired position and tighten knob74SK.

Referring to FIGS. 1-2 and 13, persons skilled in the art shouldrecognize that front plate 74, pivot arm 71 and/or chopping trunnion 73may pivot together about a bevel axis 63A. Such bevel axis 63A may besubstantially horizontal and is preferably substantially perpendicularto axis 73A.

It is preferable that bevel axis 63A not be coplanar with the supportsurface of table body 41. Furthermore, it is preferable to locate abevel axis 63A which provides two bevel positions where the distancebetween the support surface of table body 41 and the end of cuttingwheel 76 are substantially equal. Referring to FIG. 14, such bevel axis63A can be located by first selecting the two bevel positions of cuttingwheel 76, and determining the angle difference X between both bevelpositions.

In the present embodiment, the two bevel positions are 0° and 45°,whereas angle difference X is 45°. Then, the lowermost corner of cuttingwheel 76 when cutting wheel 76 is in the 0° bevel position and which isthe corner farthest away from the cutting wheel 76 in the 45° bevelposition is selected. An imaginary line IL is drawn from said lowermostcorner at an angle Y off the plane containing said lowermost corner andbeing parallel to cutting wheel 76 when cutting wheel 76 is in the 0°bevel position. Angle Y is preferably half of angle difference X.

Persons skilled in the art will recognize that imaginary line ILintersects the plane of cutting wheel 76 when cutting wheel 76 is in the45° bevel position at a point above the support surface of table body41. Bevel axis 63A can then be selected from any point of imaginary lineIL, as all points in imaginary line IL will result in a bevel axis wherewhich provides two bevel positions where the distance between thesupport surface of table body 41 and the end of cutting wheel 76 aresubstantially equal.

Referring to FIGS. 1-2 and 13, bevel trunnion 63 may include a plate 62with a slot 62S. A knob 73K extends through slot 62S and threadinglyengages chopping trunnion 73. With such arrangement, the user can fixthe bevel angle by tightening knob 73K.

A bevel pointer 75 may be attached to the pivot arm 71 and/or frontplate 74 via screw 75S so that bevel pointer 75 can pivot jointlytherewith. The user can then determine the bevel angle of cutting wheel76 by looking at the position of bevel pointer 75. Preferably, a bevelangle scale or indicia 611 is disposed on arm body 61 to further assistin the determination of the present bevel angle.

It is preferable to provide an air intake to direct cooling air towardsmotor 78M. Referring to FIG. 24, motor housing 78 may have an intake 78Idisposed on or near the top of motor housing 78, through which air canenter motor housing 78. Persons skilled in the art should recognize thatit is preferable to draw cooling air from the area above motor housing78, rather than the area below motor housing 78, as the concentration ofairborne contaminants is lower in the former than in the latter. Intake78I preferably faces forwardly and/or away from cutting wheel 76, ratherthan facing cutting wheel 76.

Motor housing 78 may have first baffles 78B disposed internally to causechanges in the direction or velocity of the airflow. Such interruptionsin the steady flow of air will preferably separate particulate matter78FD from the air and/or to fall within motor housing 78 before theyreach motor 78M.

It may also be preferable to dispose a second baffle 78DS between theairflow and the brush box 78BBB, which supports a motor brush 78BB whichin turn contacts motor 78M. Such second baffle 78DS would collectparticulate matter 78FD from the air by redirecting the airflow awayfrom brush box 78BBB.

It may be advantageous to provide a filter 78F somewhere in the airflow.Filter 78F may be made of open cell foam, or other suitable filteringmaterial. Filter 78F may be disposed near a drain 78E, so that any fluidcollected by filter 78F can exit motor housing 78 via the drain 78E.Persons skilled in the art will recognize that, even though drain 78E isdisposed on a bottom surface of motor housing 78 and that cooling airwith a higher concentration of airborne contaminants may come in throughdrain 78E, such air may be filtered by filter 78F. Persons skilled inthe art should also recognize that it is preferable to design filter 78Fso that it can easily be removed through drain 78E and/or intake 78I.

Referring to FIGS. 1-2, 12-13 and 16, outlet 53 is preferably disposedin parallel with motor 78M. Outlet 53 and motor 78M preferably receivepower via cables 54 which are connected to a plug 55. Preferably, plug55 is a ground fault circuit interrupt (GFCI) which trips a breaker(thus shutting off power) within about 50 milliseconds if the currentexceeds about 5 milliamperes. Persons skilled in the art will recognizethat outlet 53 may also be a GFCI outlet.

Switch 92 is preferably a single throw, double pole switch connected toboth cables 54 and disposed between plug 55 and outlet 53/motor 78M. Itis preferable that switch 92 be placed on arm body 61, so that itremains stationary, even when motor assembly 78 is beveled.

As mentioned above, motor assembly 70 preferably includes guard assembly80. Referring to FIGS. 1-2, 13 and 17, guard assembly 80 partiallycovers cutting wheel 76. Guard assembly 80 may include a guard body 81,which partially covers at least the upper portion of cutting wheel 76.Guard body 81 is preferably pivotably attached to pivot arm 71 so thatit can rotate about wheel axis WA.

Preferably, guard body 81 has a curved slot 82S, where the radii of thecurved slot meet at a center, which is substantially aligned with wheelaxis WA. A screw 82 may extend through slot 82S and pivot arm 71 andthreadingly engage a knob (not shown). This knob can be rotated to fixthe pivotal position of guard body 81 relative to pivot arm 71. Thisallows guard body 81 to pivot relative to pivot arm 71 to cover thespindle 71 when a smaller cutting wheel (such as 76′ in FIG. 17B) isinstalled thereon. In addition, such arrangement allows the guard body81 to remain in the same pivotal position relative to cutting wheel 76regardless of the cutting wheel diameter. This is especially helpful formaintaining the fluid delivery assembly 100, discussed below, alignedwith cutting wheel 76.

Referring to FIGS. 1 and 18-21, guard assembly 80 may support fluiddelivery assembly 100, which directs water and/or other fluids towardscutting wheel 76 for cooling cutting wheel 76 during the cuttingoperation. Fluid delivery assembly 100 comprises a hose 102 which isconnected to and feeds fluid to a valve body 101.

Valve body 101 may be attached to guard body 81. In particular, valvebody 101 may have a notch 101N which receives a screw 81S threadinglyengaged to guard body 81. Valve body 101 in turn may send the fluid totwo nozzles 104, each nozzle 104 being disposed on opposite sides ofcutting wheel 76. Nozzles 104 in turn have holes 104H through which thefluid exits.

Nozzles 104 are preferably carried by a carrier 103, which may bepivotably attached to valve body 101. Carrier 103 may be connected topivoter 105. This enables the user to rotate nozzles 104 and/or carrier103 to a desired position towards or away from cutting wheel 76 byrotating pivoter 105. Pivoter 105 preferably has a handle 105H tofacilitate such rotation.

Preferably, nozzles 104 and/or carrier 103 can be biased away fromcutting wheel 76 so that the fluid exiting through holes 104H does notcontact cutting wheel 76. This placement advantageously reduces theamount of fluid misting.

It is preferable that nozzles 104 may be made of an elastic or resilientmaterial such that, when a workpiece T is pushed into contact withcutting wheel 76, workpiece T flexes nozzles 104 as shown in FIG. 19, sothe exiting fluid can contact and/or cool cutting wheel 76. Makingnozzles 104 of an elastic or resilient material may also prevent damageto nozzles 104 and/or fluid delivery assembly 100 when the workpiece Tis returned to the original position as nozzles 104 would safely flexout of the way, as shown in the broken line position in FIG. 19.

Referring to FIGS. 20-21, each nozzle 104 may have a rib 104R protrudingtherefrom. Rib 104R is preferably disposed above hole 104H to redirectthe air flow AF created by the rotating cutting wheel 76. Suchredirection allows the fluid flow FF exiting through nozzle hole 104H toremain in a laminar-type flow until it contacts cutting wheel 76 withoutdisturbance from air flow AF, thus reducing fluid misting.

It is preferable to provide an easy means for separating hose 102 fromvalve body 101. Referring to FIG. 21, hose 102 may include an elbow102E, which has a plate 102P. Plate 102P can be inserted into an input101I of valve body 101. A plate 106 rotatably attached to valve body 101may have a slot 106S which captures plate 102P to maintain hose 102connected to valve body 101. Persons skilled in the art will recognizethat plate 106 may be rotatable attached to valve body 101 via a screw106P. Persons skilled in the art may also recognize that it ispreferable to provide plate 106 with a tab 106T to enable the userbetween the retaining position and the plate bypassing position shown inFIG. 21.

Guard assembly 80 may also have other means for controlling fluid flow.For example, referring to FIG. 22, guard body 81 may have internalbaffles 81B and/or a bottom wall 81W, which may be disposed as close aspossible to cutting wheel 76. As cutting wheel 76 rotates along path BR,it carries fluid, fluid spray and/or mist. Internal baffles 81B and/orbottom wall 81W catch the fluid, spray and/or mist off the rotatingcutting wheel 76 and redirect such fluid to the rear of guard body 81,where it can be released into base 11.

Guard assembly 80 may also have a flapper 83 attached to guard body 81.Flapper 83 may be made of rubber. Flapper 83 preferably has an upperportion 83R with substantially vertical ribs and a lower portion 83Swithout ribs. Such arrangement is advantageous as the ribs on the upperportion reduces the amount of mist created when fluid strikes flapper83, whereas the lower portion 83S can lay flush on workpiece T and actas a wiper.

Persons skilled in the art may recognize other alternatives to the meansdisclosed herein. However, all these additions and/or alterations areconsidered to be equivalents of the present invention.

What is claimed is:
 1. A saw comprising: a base; a frame assemblydisposed on the base; a first rail disposed on the frame assembly; atable slidingly disposed on the first rail, the table having an uppersurface for supporting a workpiece; a support assembly disposed on theframe; and a saw assembly supported by the support assembly, the sawassembly comprising a motor, a motor housing covering the motor, acutting wheel driven by the motor, and a guard covering an upper portionof the cutting wheel, wherein the motor housing has an inlet forallowing air into the motor housing, an airflow path for directing airflow though the motor housing to the motor, and a filter within themotor housing, wherein the airflow path includes baffles projecting andoverlapping from opposing inner surfaces of the motor housing in adirection perpendicular to the airflow path, to change the direction ofthe air flow.
 2. The saw of claim 1, wherein the inlet lies in a planesubstantially perpendicular to the blade.
 3. The saw of claim 1, whereinthe inlet is disposed on the motor housing to draw air from above themotor housing.
 4. The saw of claim 1, wherein the airflow path isconfigured to remove particulate matter from the air that enters theinlet.
 5. The saw of claim 1, further comprising a brush box forsupporting a brush for the motor.
 6. The saw of claim 5, wherein atleast one baffle is disposed between the airflow path and the brush boxto remove particulate matter from the air.
 7. A saw comprising: a base;a rail disposed on the base, the rail having a longitudinal axis; atable having at least one bearing that rides along the rail to enablethe table to slide relative to the base in a direction of thelongitudinal axis; a fluid collection pan coupled to the base anddisposed below the table; and a support assembly disposed on the baseand supporting a saw assembly above the table, the saw assemblycomprising a motor, a motor housing covering the motor, a cutting wheeldriven by the motor, and a guard covering an upper portion of thecutting wheel, wherein the motor housing has an inlet for allowing airinto the motor housing, and at least one first baffle and at least onesecond baffle defining an airflow path within the motor housing, betweenthe inlet and the motor, for directing air flow through the motorhousing to the motor, and for removing particulate matter from the air,wherein the at least one first and second baffles project from opposinginner surfaces of the motor housing and overlap in a directionperpendicular to the airflow path, to change the direction of the airflow.
 8. The saw of claim 7, wherein the inlet lies in a planesubstantially perpendicular to the cutting wheel.
 9. The saw of claim 7,wherein the inlet is disposed on the motor housing to draw air fromabove the motor housing.
 10. The saw of claim 7, further comprising abrush box for supporting a brush for the motor.
 11. The saw of claim 10,wherein the at least one second baffle is disposed between the airflowpath and the brush box to remove particulate matter from the air.